Installation

RESEARCH&DEVELOPMENT OF AMERICA, INC.
5420 DANIELS STREET STE A, CHINO CA., 91710 · (800)634-9166 · (909)628-4722 · FACSIMILE (909)591-2198
www.yoshimura-rd.com
YOSHIMURA PERFORMANCE EXHAUST SYSTEM
SUZUKI
2000-2012
DR-Z 400S/M
!
2166502
2166503
STAINLESS STEEL FULL SYSTEM WITH CF SLEEVE
STAINLESS STEEL FULL SYSTEM WITH ALUMINUM SLEEVE
THIS PRODUCT IS DESIGNED FOR USE IN CLOSED COURSE
RACING AND IS NOT INTENDED FOR ANY OTHER USE.
!
NOTE: IN THE STATE OF CALIFORNIA, IT IS ILLEGAL TO MODIFY THE EMISSION CONTROL SYSTEM, WHICH INCLUDES THE CARBURETORS OF ANY VEHICLE.
Installation Procedures:
Page 2
Caution: Exhaust system can be extremely hot. Let motorcycle cool
down before beginning installation.
Note: Read through all instructions before beginning installation.
Tools Needed:
Metric socket set
3/8” ratchet and extension
Allen bit set for torque wrench
Torque wrench
Installation Steps:
1. Remove right rear number plate (see Fig. 1).
2. Remove stock exhaust system and stock exhaust port
gasket. Note: Remove stock rubber grommet from muffler
mount.
3. Install new exhaust port gasket (Suzuki part number
14181-29E02).
4. Install Yoshimura header using stock header nuts. Do not
tighten at this point.
Fig. 1
Stock Muffler Mount
Stock Chassis Mount
5. Install muffler and tail-pipe onto header.
6. Bolt tail-pipe to stock chassis mount using supplied bolt
(see Fig. 2). Do not tighten bolt at this point.
7. Mount muffler to stock muffler mount location using a mix
of stock and supplied bolt, washers, and aluminum spacer
(see Fig. 3 and Parts Diagram for orientation) .
8mm Nut
8MM Large
Washer
Chassis
Aluminum
Spacer
Aluminum
Insert
Fig. 2
8MM Large
Washer
8mm x 60mm
Hex Head Bolt
Muffler
Mounting
Bracket
Fig. 3
Installation Procedures:
8. Torque chassis mount bolt and muffler mount bolt
to 2.5 kg-m (18 lb-ft).
9. Torque header nuts to 2.0 kg-m (14.6 lb-ft).
10. Install Yoshimura heat shield onto Yoshimura
tailpipe using supplied heatshield bolts.
11. It is recommended that the entire exhaust system
be wiped down with rubbing alcohol to remove oil
and fingerprints. This will help prevent tarnishing
of the finish after the exhaust is heated up.
12. Before starting motorcycle check for proper
clearance between new exhaust system and rear
suspension (i.e. rear brake, frame, shock spring,
etc). If any problem is found, please carefully
follow through the installation steps again. If
problem still persists, please call Yoshimura
technical department at (800)634-9166 / in CA
(909) 628-4722 .
13. Reinstall number plate.
14. Check for proper clearance between new exhaust
system and number plate.
Note: After starting motorcycle, it is normal for
new exhaust system to smoke until oil residue
burns off.
Page 3
Part List:
Page 4
2166502, 2166503
Parts Diagram
6 9
10
5
S
4
8
2
3
S
Heat Shield Mounts
8
7
S=Stock
11
12
1
NO.
DESCRIPTION
1 Yoshimura Header
Stainless Steel
2 Yoshimura Tailpipe
Stainless Steel
3 Muffler Assembly
RS2 Muffler with Aluminum Sleeve
RS2 Muffler with Carbon Fiber Sleeve
4 8mm x 60mm Socket Head Bolt
5 Large Washer
6 Aluminum Insert
7 8mm x 30mm Flange Hex Bolt
8 Medium Exhaust Springs
9 Muffler Mount Spacer
10 8mm Flange Nut
11 Yoshimura Heatshield
12 6x8mm Button Head Flange Screw
** Offroad Endcap Plug
** Spring Puller Tool
** Rubber Grommet
** 3mm Flat Washer
** Yoshimura Vinyl Sticker
QTY
1
PART #
2166-101
1
2166-144
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
2166503-RMA
2166502-RMA
M8X60H
8MMWASHERL
ALS-003
M8X30H
RACE-SPS-1
2166-SPCR
8MMNUT
2165-HS
RC116HSB
347PLUG
ST-200
Z1022
3MMWASHER
17029
RESEARCH&DEVELOPMENT OF AMERICA, INC.
5420 DANIELS STREET SUITE A, CHINO, CA 91710 · (800)634-9166 · (909)628-4722 · FACSIMILE (909)591-2198
www.yoshimura-rd.com
S p a r k A r r e s t e r C l e a n i n g Information
5
2
4
2
3
Parts Diagram
Caution: Muffler can be extremely
hot. Let muffler cool down
before removing spark
arrester.
Note:
NO.
1
2
3
4
5
Read through all
instructions before
beginning disassembly.
QTY
1
5
1
1
1
3mm Allen Key
Wire Brush
Pair of Gloves
Safety Glasses
Using a wire brush, remove carbon deposits from
spark arrester screen. Inspect the screen for
excessive wear or damage. If spark arrester is
excessively worn or damaged, the spark arrester
must be replaced. Cleaning and inspection should
be performed after every 60 hours of use.
Cleaning Steps:
CAUTION: Gloves and Safety Glasses should be
worn while cleaning spark arrester.
Tools Needed:
1
2
Using a 3mm Allen key, remove the three 5mm x
10mm button head bolts that secure the cone cap
to the muffler (see Parts Diagram for location).
Remove the two 5mm x 10mm button head bolts
that secure the spark arrester to the muffler.
Remove the spark arrester from the muffler.
3
DESCRIPTION
Cone Cap
5mm x 10mm Button Head Bolt
Exhaust Tip
Spark Arrester
Muffler Assembly
4
Re-install spark arrester and cone cap. Torque the
5mm x 10mm bolts to 1.0 kg-m (7.3 lb-ft).
NOTE: It is recommended that a low strength
“Loc-tite” is used on the 5mm x 10mm bolts.